Process for dynamic design of pile foundation systems using tunable pile members capable of absorbing vibrations

ABSTRACT

There is disclosed a process for making a foundation system for a platform. In an embodiment, the process includes obtaining design data relating to load and soil characteristics; performing modal tests on a pile member installed in soil to determine natural frequency of the pile member; performing vibration tests on a pile member to determine stiffness; forming a model of using data obtained; testing, in silico, how the model responds to frequencies in a range of the equipment; adjusting, in silico, the model to satisfy design criteria; forming, in silico, a plan of a foundation system based on the adjusted model; installing the foundation system based on the plan; performing vibration tests on the installed foundation system, and measuring vibration levels; and adjusting the foundation system to avoid resonance at a natural frequency by one of stiffen vibrations or dampen vibrations. Other embodiments are also disclosed.

REFERENCE TO PENDING PRIOR PATENT APPLICATION

This application is a division of pending prior U.S. patent applicationSer. No. 13/744,178, filed Jan. 17, 2013 by Bernard J. Gochis forPROCESS FOR DYNAMIC DESIGN OF PILE FOUNDATION SYSTEMS USING TUNABLE PILEMEMBERS CAPABLE OF ABSORBING VIBRATIONS, which claims the benefit under35 U.S.C. 119(e) of U.S. Provisional Patent Application Ser. No.61/588,156, filed Jan. 18, 2012 by Bernard J. Gochis for “PROCESS FORDYNAMIC DESIGN OF PILE FOUNDATION SYSTEMS USING TUNABLE PILE MEMBERSCAPABLE OF ABSORBING VIBRATIONS,” which patent application is herebyincorporated herein by reference.

BACKGROUND

Conventionally, a pile foundation system generally includes a skid orplatform connected with (i.e., welded to) a plurality of pile membersthat have been driven into the ground. This type of foundation systemworks well with traditional loads that rest on the skid or platform,such as building structures. One benefit to pile foundation systems isthat they can be installed without the need for concrete foundations.

As recognized by the present inventor, where a structure or load is tobe supported by a pile foundation system and the structure or load willvibrate or oscillate significantly when in place on the platform (i.e.,natural gas compressors which reciprocate in a manner that causesvibration), conventional pile foundation systems may also vibrate.

Accordingly, as recognized by the present inventor, what is needed arepile members that are capable of absorbing vibration, and a process fordynamically designing a pile foundation system using tunable pilemembers that are capable of absorbing vibration.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key aspects oressential aspects of the claimed subject matter. Moreover, this Summaryis not intended for use as an aid in determining the scope of theclaimed subject matter.

In an embodiment, there is provided a foundation system for supportingequipment on a platform, the foundation system capable of harmonicresonation at a natural frequency due to movement of the equipment onthe platform, the foundation system comprising one or more vertical pilemembers, each vertical pile member having a first end adapted to bedriven into the ground and a second end adapted to be connected with abottom portion of the skid platform; and one or more tunable pilemembers, each tunable pile member having a lower portion adapted to bedriven into the ground and an upper portion adapted to be connecteddirectly or indirectly with the skid platform, each tunable pile memberadapted to receive an insert member between the upper and lowerportions, so that the stiffness of the tunable pile member can beadjusted.

In another embodiment, there is provided a process for making afoundation system for a platform, the foundation system capable ofharmonic resonation at a natural frequency due to movement of theequipment on the platform, including the steps of a) obtaining designdata relating to the load and the soil characteristics; b) performingone or more modal tests on a pile member installed in the soil todetermine the natural frequency of the pile member; c) performing one ormore vibration tests on a pile member installed in the soil to determinethe stiffness of the pile member; d) forming a model the foundationsystem using the data obtained in steps a)-c), the model including askid platform, vertical pile members, and adjustable pile members; e)testing, in silico, how the model responds to frequencies in the rangeof the reciprocating equipment; f) adjusting, in silico, the model tosatisfy design criteria; g) forming, in silico, a plan of a foundationsystem based on the adjusted model; h) installing the foundation systembased on the plan; i) performing vibration tests on the installedfoundation system, and measuring vibration levels; and j) adjusting thefoundation system to avoid resonance at a natural frequency by one ofstiffen vibrations and dampen vibrations.

In yet another embodiment, there is provided a process for making afoundation system for a platform, the foundation system capable ofharmonic resonation at a natural frequency due to movement of theequipment on the platform, including the steps of a) obtaining designdata relating to the load and the soil characteristics; b) performingone or more modal tests on a pile member installed in the soil todetermine the natural frequency of the pile member; c) performing one ormore vibration tests on a pile member installed in the soil to determinethe stiffness of the pile member; d) forming a model the foundationsystem using the determined natural frequency of the pile member dataobtained in steps a)-c), the model including a skid platform, verticalpile members, and adjustable pile members; e) testing, in silico, of howthe model responds to frequencies in the range of the reciprocatingequipment; f) adjusting, in silico, the model to satisfy designcriteria; h) forming, in silico, a plan of a foundation system based onthe adjusted model; i) installing the foundation system based on theplan; j) performing vibration tests on the installed foundation system,and measuring vibration levels; and k) adjusting the foundation systemto avoid resonance at a natural frequency by one of stiffen vibrationsand dampen vibrations.

Other embodiments are also disclosed.

In light of the above and according to some embodiments, disclosedherein are various embodiments of pile foundation systems usinginventive tunable pile members that are capable of selectively absorbingvibration. Also disclosed herein are processes for dynamically designingpile foundation systems using tunable pile members. Also disclosedherein are jack bolts that can be connected to a pile member to engage aportion of a platform in order to provide for leveling of the platform,and shim tubes which may be used for connecting pile members to portionsof a platform.

In one example, a process for dynamically designing a pile foundationsystem can provide the required stiffness so as not to excite (andthereby prevent) the natural frequency of the foundation system fromharmonically resonating. As disclosed herein, this process can includepreliminary on-site vibration testing that provides pile stiffnessvalues; modal testing (i.e., bump tests) to determine the frequency ofpiles; static testing to verify soil density; skid/platform modelingusing Finite Element Analysis (FEA) to determine the natural frequencyof the skid.

In one example, field and pile results are input into the FEA modelwhich is simulated on a computer to determine if a harmonic resonancewould occur within the operating speed range of the heavy reciprocatingequipment that is to be supported by the foundation system. If harmonicresonance would occur, piles (including tunable pile members) can beadded, removed or relocated until the simulation results are acceptablein terms of minimizing vibration/resonance.

Once the model simulation is confirmed as being acceptable, the pilelayout plans are created and, depending on the layout design plans, theplans may use vertical piles, battered piles, any or all of which may betunable piles. The piles are installed into the ground according to thepile layout plans. Once the piles are installed into the ground andtheir position, height, level and any other parameters are confirmed,the skid is lowered onto the piles, the skid foundation is leveled, andthe piles are welded to the skid.

If needed, shim tubes (described below) can be used to bridge any gapsbetween the tops of any piles and the bottom of the skid. In anembodiment, the shim is positioned around the outer diameter of the topof the pile and welded to both the pile and the bottom of the skid.

Also, if needed, jack bolts can be attached to the top portions of pilemembers. Jack bolts may be adjusted to raise the level of the skid atthe location of the pile, in order to help level the foundation ifneeded. Once the skid has been leveled and connected (i.e., welded) withthe pile members, before startup of the equipment, the skid is testedwith shakers and sensors that are placed on the skid, to confirm thereare no unacceptable levels of harmonic resonance or vibration within theoperating speed of the equipment. If there is an unacceptable level ofharmonic resonance or vibration, one or more piles are adjusted. Forinstance, one or more tunable pile members can be dampened, one or moretunable pile members can be stiffened, or one or more tunable pilemembers can be dampened while one or more tunable pile members can bestiffened, which can help reduce vibration of the foundation. Once thevibration testing confirms that there are no unacceptable levels ofharmonic resonance or vibration within the operating speed of theequipment, the equipment on the skid is turned on. Additionalfine-tuning adjustments to the tunable piles can still be made ifdesired.

Additional objects, advantages and novel features of the technology willbe set forth in part in the description which follows, and in part willbecome more apparent to those skilled in the art upon examination of thefollowing, or may be learned from practice of the technology.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present invention,including the preferred embodiment, are described with reference to thefollowing figures, wherein like reference numerals refer to like partsthroughout the various views unless otherwise specified. Illustrativeembodiments of the invention are illustrated in the drawings, in which:

FIGS. 1 and 2 illustrate examples of foundation platforms with verticalpiles, angled piles, and tunable piles, in accordance with variousembodiments.

FIG. 3 illustrates an example of tunable battered piles in an openconnection configuration, wherein no inserts have been installed.

FIGS. 4 and 5 illustrate examples of tunable piles, wherein a solidconnection is formed using a steel disc insert, in accordance with oneembodiment.

FIG. 6 illustrates an example of a tunable pile having a dampenedinsert, in accordance with one embodiment.

FIGS. 7 and 8(a)-8(c) illustrate examples of processes for installing atunable pile for use in a foundation, in accordance with one embodiment.

FIGS. 9(a) and 9(b) illustrate an example of tunable piles, inaccordance with an embodiment.

FIG. 10 illustrates an example of a dynamic design process, inaccordance with one embodiment.

FIGS. 11A(a)-11A(d) and 11B(a)-11B(c) illustrate example tests that canbe run as part of the dynamic design process of FIG. 10.

FIGS. 12(a)-12(b), 13(a)-13(b), and 14(a)-14(b) illustrate examples ofjack bolts for connecting a pile to a portion of a platform in order toprovide for leveling of the platform, in accordance with one embodiment.

FIGS. 15 and 16(a)-16(d) illustrate examples of shim tubes which may beused for connecting pile members to portions of a platform, inaccordance with one embodiment.

FIG. 17 illustrates an example of support locations on the bottom sideof an example of a skid where piles can be connected, in accordance withan embodiment.

FIG. 18 illustrates an example of a pile layout design for supporting askid, in accordance with one embodiment.

FIGS. 19 and 20 illustrate examples of a shaker placed on a skid, inaccordance with one embodiment.

FIG. 21 illustrates an example of sensors placed at various locations ona skid, in accordance with one embodiment.

FIGS. 22(a)-22(c) illustrate an example of a tunable pile member inthree different configurations, in accordance with one embodiment.

FIGS. 23 and 24 illustrate an example of an installation of tunable pilemembers prior to installation of a platform.

FIG. 25 illustrates a shaker together with a sensor disposed at a singletunable pile member.

FIG. 26 illustrates a platform during placement onto a plurality oftunable pile members.

FIG. 27 illustrates the tunable pile members selectively attached to theplatform during installation and testing of the required stiffness so asnot to excite (and thereby prevent) the natural frequency of thefoundation system from harmonically resonating.

FIG. 28 illustrates a shaker and a sensor disposed on the platform inconnection with the foundation system of the tunable pile system duringtesting of the required stiffness so as not to excite (and therebyprevent) the natural frequency of the foundation system fromharmonically resonating.

FIG. 29 illustrates the platform installed onto the foundation system ofthe tunable pile members.

FIG. 30 illustrates the platform of FIG. 29 in which backfill or othermaterial covers the foundation system of the tunable pile members to theedge of the platform.

DETAILED DESCRIPTION

Embodiments are described more fully below in sufficient detail toenable those skilled in the art to practice the system and method.However, embodiments may be implemented in many different forms andshould not be construed as being limited to the embodiments set forthherein. The following detailed description is, therefore, not to betaken in a limiting sense.

Disclosed herein are various embodiments of pile foundation systemsusing tunable pile members that are capable of selectively absorbingvibration, and processes for dynamically designing pile foundationsystems using tunable pile members. Also disclosed herein are jack boltsthat can be connected to pile members for engaging a portion of a skidplatform in order to provide for leveling of the platform, and shimtubes which may be used for connecting (i.e., welding) pile members toportions of a platform.

Pile Foundation Systems Using Tunable Pile Members

Referring to FIGS. 1-2, examples of foundation systems 5 are shownincluding foundation platforms 10 (also referred to as skids 10)connected with and supported by vertical pile members 15, angled pilemembers 20, and tunable pile members 15 or 20 that have been screwed ordriven into the ground, in accordance with embodiments. The skidplatform 10 is adapted to support a variety of loads, such as but notlimited to structures or equipment 25 (i.e., reciprocating loads,natural gas processing equipment, heavy equipment) or other items.

The skid platform 10 is connected (i.e., welded or otherwise attached)at multiple locations to a plurality of vertical piles 15 and angledpiles 20 (referred to herein also as “battered piles 20”) that have beendriven into the ground. FIG. 17 shows an example of different locationswhere piles can be connected to a skid 10. As described herein, one ormore tunable piles 15 or 20 are used to support the platform 10 and toreduce or dampen the oscillation or vibration of the skid platform 10when the load 25 vibrates or oscillates.

As shown in FIGS. 3-6 and 22, in accordance with an embodiment, atunable pile member 15 includes a lower pile member 30, an upper pilemember 35, and a tunable insert portion 40 positioned between the upperpile member 35 and the lower pile member 30. The lower pile member 30has one end 45 configured to be driven into the ground and at theopposing free end includes a flange 50 or bearing surface 50 which isadapted to securely receive the tunable insert portion 40.

The upper pile member 35 at one end is adapted to be connected (i.e.,welded or otherwise attached) to the skid platform 10 (directly orindirectly via a connection 55 to a vertical pile member 15 that isconnected or configured for connection to the platform 10), and at theopposing free end includes a flange 60 or bearing surface 60 which isadapted to be securely receive the tunable insert portion 40.

Both flanges 55, 60 may include a plurality of corresponding and alignedopenings 65 (FIG. 8), through which bolts 70 (FIGS. 4-8) can be passedto secure the tunable insert portion therein.

The tunable insert portion 40 is positioned between the lower flange 50of the lower pile member 30 and the upper flange 60 of the upper pilemember 35. The tunable insert portion 40 is adapted to define thedampening characteristic of the tunable pile member 20. In one example,and with reference to FIG. 3, the tunable pile member 20 may be used inan open configuration wherein no insert portion 40 is positioned betweenthe upper pile member 35 and lower pile member 45. This openconfiguration offers no dampening for the skid platform 10 from thetunable pile member.

In another exemplary embodiment, and with reference to FIGS. 4 and 5, atunable insert portion 40 may include a rigid steel disc 75 that isinserted between the upper pile member 35 and lower pile member 45 toform a rigid/solid connection. The steel disc 75 may include a pluralityof openings through which bolts 70 can be passed to secure the disc tothe upper and lower flanges of upper and lower pile members. Thisconfiguration offers dampening for the platform in the sense thatvibrations from the platform are transferred along the tunable pilemember to the ground.

In another exemplary embodiment, and with reference to FIG. 6, a tunableinsert portion 40 may include a dampening material 80 or a vibrationabsorbing material 80, such as, but not limited to, Korfund. The type ofmaterial and characteristics of the material will depend upon theparticular implementation, including factors such as the amount ofvibration absorption that is desired by the tunable pile member, and thefrequency and magnitude of vibrations that occur on the platform.

In the exemplary embodiment of FIG. 6, the tunable insert portion 20includes a first lower absorbing layer 80 (which can be made of amaterial such as Korfund or other material), a steel disc layer 75, anda second upper absorbing layer 80 (which can be made of a material suchas Korfund or other material)—all positioned between the lower flange 50of the lower pile member 30 and the upper flange 60 of the upper pilemember 35. The absorbing layers 80 and the steel disc layer 75 mayinclude a plurality of openings 65 through which bolts 70 can be passedto secure the layers to the upper flange 60 and lower flange 50 of upperpile member 35 and lower pile member 30. This configuration offersdampening for the platform 10 in the sense that vibrations from theplatform 10 are transferred along the tunable pile member 20 anddampened or absorbed by the tunable insert portion 40.

In another exemplary embodiment of a tunable pile, instead of an angledpile member 20, a tunable pile member (not shown) can be formed in avertical orientation if desired. For instance, a tunable pile can bemade using a vertical pile member driven into the ground, and a tunableinsert portion (i.e., a dampening material insert, a steel disc insert,or an open configuration) can be attached between the top of the pileand the bottom of the platform, in one example. In other embodiments,concrete may be used as an indirect connection between portions of thetunable pile, between the tunable pile and the platform, or in otherconfigurations.

FIGS. 7-8 illustrate examples of processes for installing a tunable pilefor use in a foundation, in accordance with one embodiment of thepresent invention.

At operation 700, an angled pile member (also referred to herein as a“battered pile”) is installed and driven into the ground, and in oneexample, at an angle relative to the ground. At operation 705, thebattered pile is cut at a line above ground, thereby forming a lowerportion and an upper portion of the battered pile. At operation 710, avertical pile is installed and driven into the ground proximate thebattered pile. At operation 715, cut vertical pile, and at operation720, the upper free portion of the battered pile is installed to thevertical pile. Plates (i.e., side plates) can be installed to both theupper portion of the battered pile and to the vertical pile, in order tokeep the upper portion positioned and connected securely to the verticalpile.

At operation 725, a lower flange is installed to the lower portion ofthe battered pile. In one exemplary embodiment, the lower flange has aplurality of openings for receiving bolts. At operation 730, an upperflange (which in one exemplary embodiment has a plurality of openingsfor receiving bolts) is positioned and installed relative to the upperpile portion of the battered pile.

At operation 735, an upper absorbing material (i.e., Korfund ring) ispositioned relative to the upper flange. At operation 740, the upperflange is installed onto the upper portion of the battered pile. Atoperation 745, a lower absorbing material (i.e., Korfund ring) ispositioned relative to the lower flange of the lower portion of thebattered pile. As shown in FIGS. 4, 5, and 8, a steel disc may bepositioned between the upper absorbing material and lower absorbingmaterial if desired. At operation 750, the upper and lower flanges,along with the upper and lower absorbing materials and steel disc, arebolted together using a plurality of bolts, which thereby connects andsecures the lower portion and upper portion of the battered pile withthe tunable insert portion therebetween.

FIG. 9 illustrates examples of tunable piles 20 having been installed,in this case with metal discs 70 installed as the tunable insert portion40.

Hence, it can be seen that a foundation can be formed with one or moretunable pile members that can be selectively used to reduce or mitigatethe amount of vibration along the skid of the foundation. Moreover,through the use of tunable piles, the foundation system is adjustablefor vertical and horizontal stiffness whereas traditional systems (i.e.,concrete foundations) are not generally adjustable for horizontalstiffness.

Dynamic Design Processes

FIG. 10 illustrates an example of a dynamic process for designingfoundation systems, in accordance with one embodiment of the presentinvention. This process can be used to dynamically design and tune thepile members supporting a skid/platform of a foundation system. Asdescribed above, the foundation system may include a skid/platform forsupporting a load (i.e., structure and/or equipment such as heavyreciprocating equipment), and a plurality of vertical piles, angledpiles, and tunable piles.

In one exemplary embodiment, the process can include preliminary on-sitevibration testing (i.e., shaker testing) that provides pile stiffnessvalues once the piles have been driven into the ground; modal testing(i.e., bump tests) to determine the natural frequency of piles; statictesting to verify soil density; skid/platform modeling using FiniteElement Analysis (FEA) to determine the natural frequency of the skid.In an exemplary embodiment, field and pile results are input into theFEA model which is simulated to determine if a harmonic resonance wouldoccur within the operating speed range of the heavy reciprocatingequipment that is to be supported by the foundation system. If yes, thenpiles can be added, removed or relocated until the simulation resultsare acceptable in terms of minimizing vibration/resonance. Once themodel simulation is confirmed as acceptable, then the pile layout plansare created and depending on the layout design plans, the plans may useof vertical piles, battered piles, and tunable piles. The piles are theninstalled into the ground according to the pile layout plans. Once thepiles are installed into the ground and their position, height, leveland any other parameters are confirmed, the skid is lowered onto thepiles, the foundation is leveled, and the piles are welded to the skid.If needed, shims (as described below) can be used to bridge any gapsbetween the tops of any piles and the bottom of the skid, wherein theshim is positioned around the outer diameter of the top of the pile andwelded to both the pile and the bottom of the skid. Also, if needed,jack bolts can be attached to the top portions of pile members, whereinthe jack bolts are adjusted to raise the level of the skid at thelocation of the pile, in order to help level the foundation if needed.Once the skid has been leveled and connected (i.e., welded or otherwisejoined) with the pile members, before startup of the equipment, the skidis vibration tested with shakers and sensors that are placed on theskid, to confirm there are no unacceptable levels of harmonicresonance/vibration within the operating speed of the equipment; and ifthere is, one or more piles are adjusted, e.g., dampened or stiffened toadjust outside of the natural frequency of vibration. For instance, oneor more tunable pile members can be dampened, which can help reducevibration of the foundation. Once the vibration testing confirms thatthere are no unacceptable levels of harmonic resonance/vibration withinthe operating speed of the equipment, the equipment on the skid isturned on. Additional fine-tuning adjustments to the tunable piles canbe made if desired.

FIG. 10 shows an exemplary process. At operation 1000, design parameterssuch as the skid/platform size, site characteristics, and deflectiontolerances are gathered.

At operation 1005, on-site testing is performed which may includetesting of soil characteristics, static load testing of vertical piles,determination of the natural frequency of a pile once it has beeninstalled into the ground (i.e., modal testing through hitting the pilewith an object and measuring its response), vibration testing, or both.Vibration testing may include measuring the response (i.e., frequencyresponse) of one or more vertical piles to agitation at differentfrequencies, wherein such agitation can be created through anelectromechanical device (shaker) which vibrates at desired testfrequencies and intensities and the response can be measured withsensors connected with a computer. Operation 1005, can be used to obtainthe natural frequency of example pile members after they have beeninstalled into the ground at the site, as well as stiffness values.

At operations 1010 and 1015, based upon the information obtained fromthe on-site testing and other design parameters and characteristics, adesign for the pile foundation is created (see, for example, of FIG.18). The design is made so as to structurally support the intended loadthat will be on the skid platform, as well as to satisfy other designcriteria such as maximum deflection, wind resistance, etc. The designwill vary depending upon the particular implementation, and may includea plurality of vertical piles, angled piles, and tunable pilesdistributed and secured and into the ground for supporting the skidplatform. The design can be made account for reducing or eliminatingharmonic resonance that would result from equipment operating at itsexpected frequency. Finite Element Analysis (FEA) can be used with acomputer model of the skid to test different configurations, designs andlayouts of pile members. For each design that is modeled, the dynamicresponse can be modeled or tested at various operating speeds within theexpected operating range of the equipment that will be supported by thefoundation structure. In the foundation system plan and design that iscreated by operations 1010 and 1015, the layout of the pile members alsoincludes tunable pile members, so that once installed, the foundationsystem can be adjusted and tuned as described herein.

At operation 1020, the piles (i.e., vertical pile members, tunable pilemembers) are installed into the ground according to the plan, and theplatform is attached to the piles. In one embodiment, the tunable pilesmay be initially installed in an open configuration with no tunableinsert portions. The skid (which may include, but is not limited to, theequipment and/or other structures) is leveled, and installed and weldedonto the piles. As described herein, jack bolts can be attached to thepile members to help in leveling the skid, and shim tubes can be weldedbetween the top of a pile member and the bottom of the skid, if needed.

At operation 1025, vibration tests may be performed on the platform(see, for example, FIGS. 19 and 20 where the shaker 1900 is located onthe skid 10, and FIG. 21 where vibration sensors 1905 are connected tothe skid at various locations). The platform may be intentionallyvibrated by electromechanical devices (i.e., shakers) so as to simulatethe vibration that will occur during normal operation of the equipmenton the skid. The resulting vibrations of the skid platform may bemeasured using sensors at various points along the skid platform. Thesensors may be connected to a computer or other device(s) that cancollect and analyze the vibration data. The foundation system isadjusted or tuned as needed based upon the results from the tests, toreduce or eliminate vibration/harmonic resonance. In one example, ifmore stiffness is needed at or about one or more portions of theplatform, then one or more tunable piles may be connected using a solidsteel disc tunable insert portions, which add rigidity to the platform.

If vibration dampening is needed at or about one or more portions of theplatform, one or more tunable piles may be connected using a vibrationdampening materials as the tunable insert portions. This may beconfigured to reduce or absorb vibrations along the skid platform.

Other adjustments can be made, alone or in combination, such as, but notlimited to, adding or removing mass to or from the skid; connecting tothe skid spare piles that were installed into the ground; disconnectingpiles that are connected to the skid; or any combination of adjustmentsas described herein.

Operation 1025 may be repeated until the desired amount of dampening orvibration reduction of the platform is achieved.

Having achieved desired dampening or vibration reduction, the actualequipment (i.e., natural gas processing equipment) on the platform canbe started up for normal operation. For any remaining vibration issuesthat are experienced while the equipment is operating, the foundationsystem may be fine-tuned, for instance using one or more of thetechniques described with reference to operation 1025. If any long-termnatural frequency change occurs during the life-time of the foundation,the foundation system may be re-tuned as described herein.

FIGS. 11A and 11B illustrate various types of vibration tests that canbe performed to measure vibrational issues in a foundation system asdescribed herein. In FIG. 11, different testing set ups for vibrationtesting using different pile types, pile orientations and depths of pileare shown. Each vibration test can be used to determine the pilestiffness and natural frequency of that particular test set up. Eachvibration test can be used to generate data that can be analyzed for usein the layout and type selection of the piles. For example: For Phase ITest #1, a steel box cap on top of a 5½″ diameter pile with a single14″×¾″ helix is installed to bedrock at point A and tested; For Test #2,a battered pile is added at point B and tested; For Test #3, a batteredpile is added at point C and tested; For Test #4, a battered pile isadded at Point D and tested. Phases II-IV tests can be used with varieddiameters, helices and depths of the pile. Phases V-VI tests can be usedwith a prebuilt box frame with six vertical 4½″ diameter piles (A-F)with 14″×¾″ helices driven to different depths and tested followed byadding battered piles (G-L) and testing. Phase VII tests can be usedwherein 4½″ diameter piles can be driven vertically (point A) andbattered piles (points B and C) with various helices can be driven toshallow depths and tested. These test setups are provided by way ofexample only, and do not limit the scope of the embodiments andinventions described herein.

Hence, it can be seen that through the use of tunable pile members andthe process described in FIG. 10, a foundation system can be designed,installed, and adjusted/tuned so as to mitigate and control vibrationissues as desired. Moreover, through the use of this process, thefoundation system is adjustable for vertical and horizontal stiffnesswhereas traditional systems are not generally adjustable for horizontalstiffness.

Other Components

In the formation of pile foundations, jack bolt systems 1200 (FIG. 12)and shim tubes 1600 (FIG. 16) can also be used to secure and adjust theplatform 10 relative to the pile members 15, 20, in accordance with someembodiments described herein. Both shim tubes 1600 and jack bolts 1200may be used in the dynamic design process for engaging vertical pileswhen vertical stiffness is required. It should be understood that use ofjack bolts and shim tubes is optional, and that the embodimentsdescribed above can be used independently or in combination with thesecomponents as desired.

FIGS. 12-14 illustrate examples of jack bolts 1200 for connecting to apile member in order to engage a portion of a skid platform in order toprovide for leveling of the skid platform 10, in accordance with oneembodiment.

The jack bolt 1200 is placed about and secured (i.e., welded) about theupper end of pile 15, and when the platform 10 is placed onto the pile15, the adjustable rod with lock nut of the jack bolt is adjusted upwardwhich puts upward pressure on the platform 10 until the desired level ofthe platform is obtained. In one example, jack bolts 1200 can beconnected to each vertical pile member 15 for engaging each pile member15 to the skid platform 10, so that precise leveling of the entirefoundation structure 5 can be achieved.

When the equipment skid platform 10 is placed on the pile 35 or othertype of foundation system 5, the adjustable rod with lock nut of thejack bolt 1200 is adjusted putting upward pressure on the equipment skid10 until desired level is obtained. A jack bolt 1200 is attached (i.e.,welded) to piles or other foundation structures, as required, forequipment skid leveling to allow for precise leveling of the entire skidstructure. Additionally, when additional vertical stiffness is neededthrough the engagement of non-engaged piles, a jack bolt 1200 can beused to pre-load the pile member by lifting the skid frame prior to useof a shim tube, creating additional stiffness.

The jack bolt 1200 can be setup in at least two manners. In one manner,bar stock spacers 1205 of a jack bolt 1200 may be welded on each side ofthe pile. The bar stock spacer 1205 includes a coupler nut 1210, athreaded rod 1215 and lock nut 1220 welded to the threaded rod 1215sized appropriately to lift the equipment skid.

In another manner, push blocks or rings 1225 of jack bolt 1200 arewelded onto the pile or other foundation structure. A collar 1230 isbolted above the weld on push block or rings. The complete collar withcorresponding threaded attachment holes 1235 are bolted in place. Theoutside of the collar may include a threaded rod and threaded bolt sizedas appropriate to lift desired equipment skid. In an embodiment, hingetubes 1240 may be provide with a permanent or removable pin 1245.

After installation of the foundation system or upon a determination thatadditional non-engaged vertical piles need to be engaged to addadditional stiffness, the jack bolt 1200 is placed upon the foundationsystem, for instance, through either setup described above. After theequipment skid is placed and leveling is needed, the jack bolts 1200 areadjusted throughout the foundation system to obtain the precise desiredlevel of the platform/equipment skid. A shim tube 1600 (described below)may then be welded between the pile member and the bottom of the skid,which thereby attached the pile member to the skid; the jack bolt maythen be removed from the pile member, if desired.

FIGS. 15 and 16 illustrate examples of shim tubes 1600 which may be usedfor connecting pile members 35 to portions of a platform 10, inaccordance with one embodiment. The diameter and thickness of a shimtube 1600 can be adjusted depending on the job application. Afterinstallation of the piles in a foundation structure, the shim tube 1600is placed over all pile shafts within the foundation system prior toplacement of the equipment skid or other structures supported by theplatform or foundation system. After leveling of the platform skid, onvertical piles to be engaged with the platform, the shim tube 1600system is raised to compensate for any gaps between the platform skid 10and the pile shaft 35, and the shim tube is welded in place to both thepile member and to the bottom side of the skid creating support on allengaged pile shafts within the foundation system for the equipment.

Upon a determination that additional vertical stiffness is required, theshim tubes 1600, on pile shafts 35 that have not yet been engaged, areraised to compensate for any gaps between the equipment skid 10 and thepile shaft 35 and welded in place, thereby creating support andadditional vertical stiffness by engaging these pile shafts 35 to theskid 10. The use of the shim tubes is a high speed method to engage apile shaft to the skid without the requirement of use of an inefficientconventional bar stock or other method of shimming. FIG. 16 illustratesthe operations of using a shim tube 1600 to connect a pile to theplatform skid 10, in accordance with one embodiment.

Through the use of one or more features of embodiments as describedherein, various advantages can be realized. For example, a foundationsystem can be installed in a much shorter time period (i.e., 5 weeksfaster) than traditional foundation systems (such as traditionalconcrete foundation systems 5) for heavy reciprocating equipment 85. Inanother example, a foundation system 5 made using one or more featuresof these embodiments is adjustable and tunable for both vertical andhorizontal stiffness, wherein a traditional foundation system (i.e.,concrete foundation poured and set on the ground) is generally nottunable or adjustable.

In another embodiment, a foundation system made using one or morefeatures of these embodiments can be formed without the need to importconcrete and water to the job site. Some job sites where foundations areneeded can be in remote locations, thereby adding significant costs forhauling concrete and other materials for the installation of atraditional concrete foundation system. Moreover, concerns withtraditional concrete joint issues are alleviated because the examples ofthe foundation systems disclosed herein do not use such concrete joints.

Where corrosion is a concern, for instance in locations with highhumidity or exposure to water, with traditional concrete foundations,this concern is typically addressed by adding more concrete atsignificantly higher cost. Foundation systems made using one or morefeatures of these embodiments can be formed to address this concern byadding or increasing the wall thicknesses of piles to make the pilesmore resistant to long term corrosion, without adding significantadditional costs to the foundation.

FIG. 22 illustrates an example of a tunable pile member in threedifferent configurations, in accordance with one embodiment.

FIGS. 23 and 24 illustrate exemplary installation of tunable pilemembers 10, 20 prior to installation of a platform.

FIG. 25 illustrates a shaker 1900 together with sensors 1905 disposed ata single tunable pile member (not shown underneath the shaker 1900.)

FIG. 26 illustrates platform 10 during placement onto a plurality oftunable pile members 15, 20. FIG. 27 illustrates the tunable pilemembers in various states of connection. Tunable pile member 2700A isillustrated connected to platform 10 with shim tube 1600. Tunable pilemember 2700B is disconnected from platform 10 with shim tube 1600 alsodisconnected from platform 10. Tunable pile members may be selectivelyattached to the platform 10 during installation and testing of therequired stiffness so as not to excite (and thereby prevent) the naturalfrequency of the foundation system from harmonically resonating. Pilemembers may be selectively attached or detached from the platform 10,after its placement.

FIG. 28 illustrates a shaker 1900 and sensors 1905 disposed on theplatform 10 in connection with the foundation system of the tunable pilesystem during testing of the required stiffness so as not to excite (andthereby prevent) the natural frequency of the foundation system fromharmonically resonating.

FIG. 29 illustrates the platform 10 installed onto the foundation systemof the tunable pile members.

FIG. 30 illustrates the platform of FIG. 29 in which backfill or othermaterial covers the foundation system of the tunable pile members to theedge of the platform.

Although the above embodiments have been described in language that isspecific to certain structures, elements, compositions, andmethodological steps, it is to be understood that the technology definedin the appended claims is not necessarily limited to the specificstructures, elements, compositions and/or steps described. Rather, thespecific aspects and steps are described as forms of implementing theclaimed technology. Since many embodiments of the technology can bepracticed without departing from the spirit and scope of the invention,the invention resides in the claims hereinafter appended.

What is claimed is:
 1. A process for making a foundation system for aplatform, the foundation system capable of harmonic resonation at anatural frequency due to movement of the equipment on the platform,including the steps of: a) obtaining design data relating to the loadand the soil characteristics; b) performing one or more modal tests on apile member installed in the soil to determine the natural frequency ofthe pile member; c) performing one or more vibration tests on a pilemember installed in the soil to determine the stiffness of the pilemember; d) forming a model of the foundation system using the dataobtained in steps a)-c), the model including a skid platform, verticalpile members, and adjustable pile members; e) testing, in silico, howthe model responds to frequencies in a range of the equipment; f)adjusting, in silico, the model to satisfy design criteria; g) forming,in silico, a plan of a foundation system based on the adjusted model; h)installing the foundation system based on the plan; i) performingvibration tests on the installed foundation system, and measuringvibration levels; and j) adjusting the foundation system to avoidresonance at a natural frequency by one of stiffen vibrations and dampenvibrations.
 2. The method of claim 1, further comprising: k) operatingthe equipment and measuring vibration levels; and l) adjusting thefoundation system to avoid resonance at a natural frequency by one ofstiffen vibrations and dampen vibrations.
 3. The method of claim 1,wherein the operation of adjusting the foundation system includes addinga dampening material to one or more of the adjustable pile members. 4.The foundation system of claim 1, wherein the step of j) adjustingincludes at least one of reconfiguring one or more of the vertical pilemembers are configured to selectively connect with the bottom portion ofthe skid platform and reconfiguring one or more of the tunable pilemembers to selectively receive an insert member so that the stiffness ofthe one or more of the tunable pile members can be adjusted toreconfigure the foundation system to a required stiffness so as not toexcite and thereby prevent the natural frequency of the foundationsystem from harmonically resonating.
 5. A process for making afoundation system for a platform, the foundation system capable ofharmonic resonation at a natural frequency due to movement of theequipment on the platform, including the steps of: a) obtaining designdata relating to the load and the soil characteristics; b) performingone or more modal tests on a pile member installed in the soil todetermine the natural frequency of the pile member; c) performing one ormore vibration tests on a pile member installed in the soil to determinethe stiffness of the pile member; d) forming a model of the foundationsystem using the design data, the determined natural frequency of thepile member data, and the determined stiffness of the pile memberobtained in steps a)-c), the model including a skid platform, verticalpile members, and adjustable pile members; e) testing, in silico, of howthe model responds to frequencies in a range of the equipment; f)adjusting, in silico, the model to satisfy design criteria; h) forming,in silico, a plan of a foundation system based on the adjusted model; i)installing the foundation system based on the plan; j) performingvibration tests on the installed foundation system, and measuringvibration levels; and k) adjusting the foundation system to avoidresonance at a natural frequency by one of stiffen vibrations and dampenvibrations.
 6. The process of claim 5, wherein the step of k) adjustingincludes at least one of reconfiguring one or more of the vertical pilemembers to selectively connect with the bottom portion of the skidplatform and reconfiguring one or more of the tunable pile members toselectively receive an insert member so that the stiffness of the one ormore of the tunable pile members can be adjusted to reconfigure thefoundation system to a required stiffness so as not to excite andthereby prevent the natural frequency of the foundation system fromharmonically resonating.